Building construction



l March 14, 1939.

A. M. MCLELLAN BUILDING CONSTRUCTION Filed April 5, 1957 2 Sheets-Shea@ l March 14, 1939. A. M. MCLELLAN BUILDING CONSTRUCTION.

2 sheets-sheet 2 Filed April 3, 1937 INVENTOR.

Ww M Patented Mar. 14, 1939 r.UNITED STATES PATENT OFFECE to McLellan Steel Development corporation ol" Nevada Corporation, a

Application April 3, 1937, Serial No. 134,782

Claims.

My invention relates to the fabricated type of building construction described in my Letters Patent No. 2,053,487 and further pertains in some respects to the general type of stucco-and-steel 5 construction shown in my co-pending application Serial No. 138,118, led April 5,1937.

An object of this invention is to improve upon the aforesaid constructions by reducing the material and labor costs, particularly by the provim sion of fewer manufactured parts and more expeditious assembly and welding features.

Another object of the invention is to provide for insulating or covering the steel structural members particularly at the welds and joints to prevent corrosion.

Another object of the invention is to provide a construction and co-related method whereby the final surface of cement, stucco, or the like may be applied simultaneously with the application of the cement for protecting the joints, and whereby the cement used thruout the structure forms a practically monolithic co-extensive network enclosing a multiplicity of spaced air pockets.

Another object of the invention is the provision of a cellular cement structure re-enforced by interconnected structural elements, which elements of themselves provide all the required structural strength so that the cement may be selected for insulating, protective, moisture-resisting and like properties rather than for its structural strength. In other Words they invention seeks to provide not a re-enforced concrete structure, but rather a self-supporting and selfsufiicient steel structure protected by and finished with cement, stucco'or the' like.

Another object of the invention is to improve upon, by strengthening and simplifying, the girder described in the aforesaid patents, particularly by reducing the number of parts and the number of welds While maintaining, or improving upon, its characteristic strength.

Another object of the invention is to improve upon the so-called X-braces shown in the aforesaid patents, particularly by reducing the number of parts and increasing the strength at the Welds.

While the present invention, insofar as the features of insulation and protection of the steel members and their joints are concerned, is applicable to a wide variety of vconstructions and to constructions materially differing from those shown in the aforesaid patents, it is another object of the invention to provide the new protective and insulating features in combination Cl. 'Y2-48) with a light weight fabricated strucure embodying my arrangement of skeleton girders, diagonally inclined X-braces, and the horizontal links or tie bars.

Many other objects will appear hereinafter. I have illustrated my invention by the accompanying drawings in which:

Figure l is a diagrammatic'cross section of a fragment of a Wall to which my invention is applied.

Figure 2 is a similar cross section of a modication of the Wall shown in Figure l.

Figure 3 is a side view of a new girder construction.

Figure 4 is a horizontal cross section thereof seen on a line lof Figure 3.

Figure 5 is a front View of an assembly of interconnected X-braces for tying adjacent girders. Figure 6 is a vertical section of a wall frame constructed according to the invention.

Figure 'l is a cross section of another form of steel frame. i My invention is best described by iirst referring to the diagram Figure l which illustrates the scheme and in which the numeral l0 indicates a thin girder extending vertically with its transverse axis normal to the plane of the wall. This girder may be of any suitable construction although it is preferably of a light weight but strong open structure such as the girder shown in Figure 3.

These girders are arranged side by side vertically thruout the wall and are joined by zig-zag braces such as indicated in Figure 1 at ll and which may be of any suitable construction but which may be constructed as shown in Figure 5.

While these braces Il serve to strengthen the structure as a whole, the construction in Figure l is shown as including horizontal tie rods I2 which serve to connect the girders along the faces of the wall and which also serve as a re-enforcing and attaching means for Wire mesh or other plaster or stucco base I4 which is preferably included to re-enforce the plaster or stucco webs l5a forming the surfaces I5 of the wall. In a building one surface l5 may be built up of outside stucco, concrete, or the like while the other surface may be built up of an interior coat for decoration, insulation and the like, or the said other surface may be composed in part of the same material as that used at the exterior and then finished with hard-wall, insulating, or acoustic plasters. However, practically speaking, my invention provides that all plastic material used in the wall is inter-connected so that the wall is a monolithic structure enclosing a self-suflicient steel frame.

One of the salient features of theY invention is that the normally arranged girders and the zig-zag braces co-act to divide the wall thruout into a plurality of similar niches I8; certain of which open direct to the one surface of the frame and others of which open direct to the other surface of the frame. In each niche there is provided a light weight core I9, which, despite its light weight, and despite the fact that itl is nothing more or less than a properly shaped paper box, is suitably resistant to collapse by reason of its shape.

Each core conforms in shape to the corresponding niche I8 but is normally a loose-lit s0- that cement as at 20 and 2| may be forced into the spaces between the cores to completely cover the zig-zag braces to a slight depth, and to so cover the girder surfaces as well.

While various methods for filling all spaces between cores will suggest themselves to those skilled in the art of gunning; dashing; spraying; pouring; extruding, and otherwise forcing cement over and around cores; and while various sequences of steps will suggest themselves for fabricating this wall, I shall describe one practical method or sequence of steps.

First the girders are erected and tied by the diagonal braces and then the horizontal bars are secured in place so that a complete wall frame is constructed, which according to my invention may have all the required strength and rigidity and which does not depend upon cement or the like for re-enforcement. Now, when the wall, or a comp-lete building embodying walls, roof, partitions, floors, etc., is so framed, the cores are put in place as the cement work progresses, and this may be done before. any wire mesh or the like is applied or, the wire mesh may be applied after. the cores are installed and. before any cementing is done. Felt or paper as a part of the wire mesh or plaster base is not required where the cement is to be forced thru the wire mesh and into spaces 26 and 2I respectively; the cores beingv the required backing where the cement is to be limited in thickness as at I5a.

Now,` working from both sides. of the Wall simultaneously, or working first from one side and then from the other, cement is applied until it suitably occupies the spaces 20 and 2| respectively and until it has built up over the surfaces as at I5a to the depth required. The simplest method of applying the cement, and one for which this invention is particularly developed is known as the gunite method. By this method the cement is applied with kinetic energy or Velocity and is readily introduced to the spaces such as 20 and 2|, and where the wire mesh is already applied, thru and around, and over the mesh until the wall surfaces are ready for final finish. Later the inside wall may be finished as customarily and the surface can be treated as required; the important feature of the invention being that all structural elements may be coated and protected by cement which is to be homogeneous thruout the structure.

The form of invention illustrated diagrammatically in Figure 2 is quite similar to that shown in Figure 1 except that the .braces are horizontal only; the niches nare cubical; and the cores or boxes are cubical.

When either form of wall is nished the boxes form air cells in the structure which reduce the weight. andadd .to the insulationrand the building or wall as a whole is stronger than re-enforced concrete, lighter, and more resistant to destructive natural phenomena, particularly to wind and earthquakes.

In Figure 3 I show a girder particularly suited for use in connection with the cement method of coating all parts, since this girder is strong, light and so open that cement may form all around its elements and provide the homogeneity which characterizes both the steel and cement portions of my improved structure. This girder comprises two spaced parallel rods 25 and 25, a long zig-zag bar Z'I touching the corresponding rods at corresponding bends 28, and the horizontal links 29. Eachv link at one end is turned around one of the rods, 26 or 2I, as the case may be where the corresponding bend 28 occurs. This convolution 3U also embraces the bend of the bar 21 and thus joins the bar 21 to the corresponding part of a rod. The other end of the link as at 3I is turned around the other rod.

To join adjacent girders together in parallel relationship and for, other purposes now apparent, I provide the zig-zag bracing members 32, 32, each similar to the other.

As shown by Figures 5 and 6 respectively, each member 32 is provided with the angular bends 33, 33 so that it has a doubly zig-zag character or a similar appearance from either of two directions degrees apart. 'Ihus a member 32 may extend from a point on a vertical bar 25 lof one girder to the bar 26 of an adjacent girder at a lower elevation, thence back to a still lower elevation on bar 25. Two such doubly zig-zag members arranged with their planes in X-formation have the peculiar function of forming a generally vertically extending series of diagonally inclined Xs; with adjacent connected Xs o-ppositely inclined. Thus two such doubly zig-zag members connect four vertical rods such as 25 and 25, or connect two complete girders, to form the bracing preferred and shown particularly in this and the aforementioned patents, but in the present case with fewer welds.

By a plurality of spaced girders and double that number of zig-zag bars 32, a complete Wall frame, such as shown in Figure '7, is constructed. The horizontal bars 34 further strengthen the structure and provide for the attachment of any suitable plaster base when same is required.

It will be understood that where the ends of the links turn around the vertical bars or rods 25, 26, they provide ample shoulders upon certain of which the horizontal bars are rested, and

upon others of which the bends 33 of the zig-zag if.'

brace members 32 are rested. All convolutions may be suitably welded and all bars resting on the shoulders so provided may also be welded in place and by certain now obvious methods of erection it becomes possible to join two or more members in a single weld. Such welds have been treated fully in the aforesaid patents;' this invention being directed more to fewer such welds and the final protection of same. A

It will be apparent from Figures 3 to 6 inclusive, and particularly from Figure 6, that the new girder, and the new diagonal bracing means de scribed herein may be employed in the arrangement of parts illustrated by Figure 1, and that these light weight open members are particularly provided by the cores 36 shown particularly in Figure 6.

It will be understood that the cement may be any suitable one such as a mixture of Portland cement and a light aggregate such as a diatomaceous earth, with a view to providing light weight, heat insulation, and good appearance rather than structural strength but of course it is obvious that a modication of the invention could consist of a steel frame and the box-like cores capable of remaining erect until such time as it was completely enclosed by poured concrete. By the Gunite method I have found that very inexpensive paper boxes, of characteristic shape will serve as the cores and these need little or no water-proofing or re-enforcernent Where the cement is properly applied. Also they may serve as the one and only plaster base.

There are many possible arrangements of the zig-zag bars 21 used to form the girders and the doubly zig-zag bars 32 forming the bracing means, together with the horizontal bars, but all such various arrangements are suggestedby this invention.

Again in some cases certain of the structural parts may be omitted and in this connection I call particular attention to the various possible applications of my new combination of straight rods or vertical members such as 25 and 26 and zig-zag connecting and bracing members such as 21 and 32. Two such rods and one zig-zag member 21 form a girder; two such girders are braced in all directions and connected to form a box-column by means of two zig-zag members 32; while a plurality of such girders and twice the number of zig-zag bars 32 form a complete wall.

It will be apparent now that the links add the feature of shoulders for attachment of other parts, and serve to additionally strengthen each girder, but it will also be apparent that certain structures may be engineered Without the links, and in fact Without the horizontal bars. Accordingly in Figure 7 I have shown a Wall constructed mainly of doubly zig-zag members 32 forming the required diagonal bracing; the zig-zag members 21 forming a part of each girder, and common angle iron here shown as a substitute for round vertical rods 25 and 26. In this form the angle irons are arranged with their apexes outermost and with their minor axes normal to the plane of the wall. Each opposite pair of such angle irons is joined to form a girder by the zig-zag member 21; this member fitting snugly in the V shaped pockets formed by the corresponding angle irons and Welded thereat. The zig-zag members 32, 32 have their bends 33 abutting the bends of the member 21 and also welded as at 39 where metal of the members 32, 32 is. in contiguity with the inner surfaces 40 of the angle iron.

It will be apparent now that I have provided for fabricating light weight structures of remarkable strength mainly from common stock bars, rods, etc., and with the minimum of welded or other joints, and that I have further provided for plastering or stuccoing the wall in an efficient manner which automatically provides for protecting all steel parts with minimum additional cement, and that I have provided a homogeneous wall or housing structure thruout in which all steel is interconnected and homogeneous and all cement is in monolithic arrangement, and in which structure the major volume is nevertheless occupied with large dened air pockets suitably spaced apart and insulated one from the other and suitably imbedded below -the corresponding surfaces of the structure: which structure is strong; light Weight; low in conductivity; decorative; resistant to corrosion and peculiarly adapted to modern requirements.

I claim:

1. A building wall comprising spaced girders, spaced braces interconnecting said girders and co;- operating therewith to provide a multiplicity of similar openings intersecting both faces of the wall, and completely closed box-like cores one for and in each such opening.

2. The building wall as in claim 1 and further including cement enclosing said wall and the cores.

3. The building wall as in claim l and further including cement enclosing said wall and said cores and formulated for purposes other than providing structural strength.

4. The building wall as in claim 1 and in which said wall is structurally complete to withstand predetermined loads and in which said cement is of an insulating and protective character..

5. A building wall comprising vertical rods, horizontally directed rods welded to and tying together said vertical rods; said rods dividing the wall into a plurality of spaces intersecting both faces of the wall; and completely closed box-like cores one for and in each such space and spaced apart in all directions from adjacent boxes: by corresponding of the said bars, and cement forming both outer faces of the wall.

6. 'Ihe building wall as in claim 5 and in which said cement is extended into the spaces between said boxes to enclose all points at which said bars are welded.

7. The building wall as in claim 5 and in which said cores are composed of paper constructed to resist collapse under kinetic application of cement.

8. 'I'he building wall as in claim 5 and in which said rods co-act to provide a structurally complete Wall to withstand maximum load and in which said cement is formulated primarily for insulation and protection of the enclosed wall members.

9. In a building wall the combination of a plurality of front bars and a plurality of rear bars arranged in two parallel rows to form a frame, zig-zag members one for and connecting each front bar with the corresponding rear bar, other zig-zag members one for and connecting each front bar with the diagonally opposed rear bar; said bars and members coacting to provide defined niches in said frame some in direct communication with the front surface of the frame and others in direct communication with the rear surface of the frame, and correspondingly shaped boxes; one for and fitted in each niche, and cement completely covering said frame and boxes.

10. The wall as in claim 9 and in which said cement is extended into the spaces between said boxes and around all of said bars and members to provide a complete monolithic cellular wall in which all frame members are completely imbedded.

ARTHUR M. MCLELLAN. 

